transformation through transparency · 2021. 3. 27. · silke ramm de camejo · matthias winkler...

TRANSFORMATION THROUGH TRANSPARENCY

: FOCUS ENERGY. EFFICIENCY. TRANSPARENCY.

Visit us online: www.sick.com/industries-pa

EFFICIENCY INCREASE IN THE ENTIRE ENERGY SECTOR

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TRANSFORMATION THROUGH TRANSPARENCY

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replaced step-by-step by those with regenerative sources. Carbon capture, storage and use in power plants, cement plants or in waste-to- energy plants, power-to-X or sector coupling are only some of these vi-sionary and, in some cases already implemented, approaches. Above all, the electrolysis of water to gen-erate hydrogen promises to become an important process. Hydrogen can be easily stored and integrated into the economic cycle – this is the case as a direct source of heat energy, or as a supplement to natural gas in turbines for power generation or as a component together with CO2 in synthetic fuel. An impressive techno-logy to achieve a compensated CO2 balance.

Read about it in this booklet: Wheth-er for onshore gas flow measure-ment, emission measurements on ships, in blast furnaces under harsh conditions or digitally in the cloud –intelligent sensors from SICK create transparency and will accompany you and your data in the transforma-tion to a clean future.

>> Climate protection, energy revo-lution, reduction in greenhouse gas-es. We are living through dramatic changes. The climate change which has been predicted for many years is here and we have to face the real consequences. Rethinking is essen-tial. Continuing as before will not prevent the negative consequences – the greenhouse effect has been proven and is already happening. And to keep with the metaphor: We should not throw stones, since we are all living in this fragile glass house together. The good news: There are solutions.

The key to the rethinking process is decarbonization. With reliable data generation, SICK is already creating the most important prerequisite for limiting emissions: Transparency. Nothing can be reduced, until it is re-liably measurable and given a value. This is the basis of the CO2 tax.

That is why SICK is involved whenev-er it is necessary to make improve-ments and increase efficiency in the entire energy sector with pioneering and advanced technology. Energy flows will change all over the world. Oil tankers will be replaced by LNG (Liquid Natural Gas) tankers, which will later be replaced by hydrogen tankers. In the mid-term, fossil en-ergy suppliers will be obsolete and

VISION AND REALITY OF THE ENERGY REVOLUTION

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10 AT THE BEGINNING THERE WAS HYDROGEN Versatile gas analysis in the production of ammonia

14 FROM LAKE CONSTANCE TO THE HIGH SEAS Exhaust gas measurement by SICK conquers the seven seas

20 SOLAR ENERGY Optimizing processes in solar power plants

24 DOSAGE AND MIX MUST BE RIGHT Non-stop supply of bulk goods

28 INCREASE OF ENERGY AND RESOURCE EFFICIENCY Flow metering systems

32 CLEAN EXHAUST GAS THANKS TO EXTRACTIVE OXYGEN MEASUREMENT Monitoring of the oxidization process during desulfurization in the MEROX® process

34 SICK LOWERS BOIL-OFF GAS LOSSES FOR ENAGAS Frosty gas measurement

39 BREF: WHEN THE BEST AVAILABLE TECHNOLOGY BECOMES THE REFERENCE POINT Expertiseindust,gasandflowmeasurement

RETHINKING IS BECOMING INCREASINGLY IMPORTANT Green energy into the gas network

MEASURING TO THE LIMIT Howthe“firemasters”fromSICKsave energy with exhaust gas analysis

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34 SICK LOWERS BOIL-OFF GAS LOSSES FOR ENAGAS Frosty gas measurement

39 BREF: WHEN THE BEST AVAILABLE TECHNOLOGY BECOMES THE REFERENCE POINT Expertiseindust,gasandflowmeasurement

PLAYING IT SAFE Personal and property protection: SICK provides relief for manufacturers and operating entities

PROJECTS IN THE PIPELINE

SOME DUST HUNTERS LIKE IT WET ... Measurementofparticulateemissionsinfluegases

Imprint

Publisher:

SICK AG · P.O. Box 310 · 79177 Waldkirch/Germany Phone +49 7681 202-0

www.sick.com · [email protected]

Editors: Solvejg Hannemann · Tobias Maillard Silke Ramm de Camejo · Matthias Winkler

Layout: Solvejg Hannemann

Pictures: SICK AG, Getty Images, Shutterstock

Reproduction of individual articles is permitted with prior consent. Subject to change without notice.

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A climate-friendly and promising application is emerging for the natural gas network. Operators of gas grids can keep up with the trend to feed, transport and store re-generatively produced hydrogen in existing gas networks – without additional investment in new FLOWSIC gas flowmeters.UltrasonictechnologyfromSICKcontinuesto provide stable measurements in gas infrastructure despite changes in gas properties. Power-to-gas plants alsoprofitfromthemeasurementperformance.

RETHINKING IS BECOMING INCREASINGLY IMPORTANT

GREEN ENERGY INTO THE GAS NETWORK

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>> The need for energy remains high and will even increase worldwide in the next few years. If the energy supply is to remain secure, a smart energy mix must cover the new requirements. The share of natural gas in this mix is estimated to grow to more than 30%. Today its share is about 22%. Renewable energy gener-ated from wind, water, sun and biomass are a priority in the current climate dis-cussion – despite some supply prob-lems. Power generation fluctuates due to changing weather conditions, and the amount generated is not predictable. In addition, there is currently not enough storage space for surplus power from so-lar and wind power plants. The way out of this dilemma could be the conversion of climate-neutral power into gas generated free of CO2. In the power-to-gas process, green electricity is converted via elec-trolysis into storable gas, e.g. hydrogen. Methane or synthetic natural gas can also be stored. Producers of fuel cells profit from green hydrogen, and natural gas vehicles move in a climate-friendly manner. Energy supply with hydrogenThe power-to-gas technology has poten-tial for climate protection and is part of the energy sector just as much as CO2-free generated hydrogen. This hydrogen can certainly also be fed into and saved in existing natural gas networks. The ex-isting gas infrastructures can be used for this purpose. The green energy added to the natural gas is thus used in an eco-nomically efficient manner and is avail-able in sufficient quantities at all times.

Research teams in the European Union and Asia are examining how reliable the supply in the existing natural gas network is in principle without straining the gas consumers. Process steps are optimized and advanced. The admixture of 5% to max. 25% hydrogen to natural gas is cur-rently considered possible. Also under examination are protection from leakage in existing systems, material compatibil-ity of the pipelines and fixtures, regula-tion for explosion protection and finally the question of how the calorific value is determined and can be controlled.

Looking at gas flow metersIt is clear that the properties of natural gas change significantly when hydrogen is admixed. Many operating entities of gas networks ask whether this change has a negative effect on the measure-

ment performance of its gas flow meters. Especially in times of cost savings, addi-tional charges are pretty much a no-go.

“Of course, when feeding in hydrogen, the measuring devices already installed in the gas grid should still be in good working order,” explains Jörg Wenzel,Head of Product Marketing Services at SICK. “That is why we have taken a close look at the effects of increased admixture of hydrogen on the ultrasonic technology and tested the FLOWSIC gas flow meters for this new requirement. Ul-trasonic flow meters from SICK can mea-sure hydrogenous natural gas. Measure-ment uncertainties which result from the admixture of up to 10% hydrogen are either negligible low or are compensated by the FLOWSIC."

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What exactly does that mean?The gas flow meters from SICK are resis-tant to hydrogenous natural gas: Elec-tronic housings, electronic adapters and parts which come in contact with me-dia such as ultrasonic sensors, O-rings, flow conditioners, plugs and protective tubes. This is the result of a study by the Federal Institute for Materials Research and Testing (BAM).

The changed density and viscosity of the gas mixture as well as the new flow and sound velocity do not influence the reli-ability and quality of the measurement results of FLOWSIC gas flow meters. A recalibration is also not necessary if up to 10% by volume of hydrogen is fed in. Similar data was published in a technical report in the magazine gwf Gas + Energie in May 2013. At a 20% admixture of hydrogen, the speed of sound probably increases by 10%. The amount of hydrogen admixed in the natural gas is therefore known and the plant operator is informed of the avail-ability of the plant.

Regarding explosionsHydrogen has a different specific ignit-ability than natural gas and is in explo-sion group IIC with stricter requirements on equipment than for natural gas measurements. Explosion group IIA is sufficient for measuring natural gas. In September 2016, BAM – the Federal Institute for Materials Research and Testing – published its report entitled “Safety properties of natural gas/hydro-genmixtures”,lookingintotheeffectsof

admixing hydrogen with natural gas on explosion behavior and requirements for the explosion group.

According to the German Gas and Water Association (DVGW), work is underway to further develop the rules. The new regulation is intended to increase the admixture of hydrogen into the natural gas network to 20% by volume. It is clear based on the current publications, that the electronics and the ultrasonic sen-sors of the installed FLOWSIC600 and FLOWSIC600-XT gas flow meters from SICK meet the explosion protection re-quirements for a natural gas mix with 10% hydrogen by volume. Correction is not necessary.

A great deal of commitment with visionIn industry, very different limit values are currently being named for the admixture of hydrogen to natural gas. They range up to 25% by volume. What seems to be clear is that the proportion of hydrogen will increase steadily over the coming years. How quickly this happens will cer-tainly depend on the speed of investment and the progress made with developing power-to-gas technologies. SICK is con-tinuing to study the measuring capability of its ultrasonic measurement devices for hydrogen contents exceeding 25 % by volume and will adapt the gas flow me-ters if necessary. Operating entities of gas plants can also continue to rely on the precise custody transfer gas volume flow measurement by SICK – and power-to-gas plants as well.

“Ultrasonic gas flow meters from SICK measure natural gas containing hydrogen. Measurement uncertainties

which result from the admixture of up to 10% hydrogen are 100% compensated for by the FLOWSIC.”

Jörg Wenzel, Head of Product Marketing Services at SICK

Download white paper now: www.sick.com/8025071

POWER-TO-GAS: Admixture of hydrogen from renewable energies into the natural gas grid and the associated suitability of SICK ultra-sonic gas flow meters.

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AT THE BEGINNING THERE WAS HYDROGEN

VERSATILE GAS ANALYSIS IN THE PRODUCTION OF AMMONIA

It is the material which influences food produc-tion like no other: ammonia. As the main com-ponent in the production of nitrogen fertilizers, ammonia is used in a wide range of industrial pro-cesses due to its physical and chemical properties. The basis for the production of ammonia on an in-dustrial scale is hydrogen. Since hydrogen typically does not occur as a natural resource, it is generat-ed on a large scale by various chemical processes.

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Controlled world growthAs a starting material for a wide range of products such as fertilizer and nitric acid, ammonia is one of the most pro-duced chemicals in the world. More than 150 million tons were produced in 2018 alone. The Haber-Bosch process for am-monia synthesis is considered as one of the most important chemical processes of the 20th century and has a huge ef-fect on the world population due to its widespread use in fertilizer production. The hydrogen needed for ammonia syn-thesis is produced and purified in sever-al steps as described above in the steam reforming process. The hydrogen then reacts with atmospheric nitrogen at high pressure and temperature and becomes ammonia. The high reaction speed and material throughput requires efficient process control in every step. Continu-ously measuring extractive gas analyzers can monitor H2, CH4, CO, CO2 and NH3 and offer significant advantages com-pared to gas chromatographs thanks to their robustness and ease of use. In the ammonia synthesis, CO and CO2 would function as catalyst poison and cause salt formation. That is why they must be removed before the synthesis step. To minimize disruptions by CO and CO2, even very small amounts in the ppm range must be detected.

The highest level of gas analysisSICK offers analysis solutions for the entire ammonia synthesis process and some subsequent processes. Experts from SICK support in the selection of the right products for the respective ap-plication. The S700 and GMS800 there-fore build the foundation for customized gas analysis for process and emission monitoring for hydrogen and ammonia production. All relevant gas components for this process can be measured both with the S700 and the GMS800 – with up to three or even six different analysis modules. Different housing types are available de-pending on the measuring task, location of use and ambient conditions. This also includes a wall housing with ATEX certi-fication for explosion-hazardous areas which is suited for industrial environ-ments. Equipped with modern software, the GMS800 also features all the inter-faces required for remote monitoring via networks through to the connection to a distributed control system.

“Breadfromair” fertilizer from nitrogenNitrogen is one of the bases for the growth of plants. The nitrogen contained in the air we breathe cannot be absorbed by plants. Through ammonia synthesis and the fertilizer created in this way, ni-trogen is offered to plants in a form in which they can use it as nutrient. The “breadfromair”comparisonwascreatedduring the discovery of the Haber-Bosch process about 100 years ago. And inter-estingly, the property of “air”, or moreaccurately the composition of the gases, still plays a decisive role today in the suc-cessful process of ammonia production. Gas analysis systems with a modular de-sign are extremely useful for monitoring and guaranteeing this condition.

For example, SICK’s product range in-cludes a special solution for monitoring the efficiency of the steam reformer and control of the downstream shift con-verter by measuring methane (CH4) and carbon monoxide (CO). This solution can be implemented by SICK with the S700 or GMS800 extractive gas analyzers from SICK. However, there are different licenses available for the industrial pro-duction of ammonia with various tech-nologies. Which license is selected also depends on the raw materials used as well as the surrounding conditions. In principle, the solution described above can be transferred to other licenses for ammonia synthesis based on steam reforming. Customer and system-spe-cific adaptations required for this mea-surement can be implemented by SICK.

>> The most important processes for hy-drogen generation are steam reforming of light hydrocarbons, partial oxidation of hydrocarbons or carbon and water elec-trolysis. Steam reforming of natural gas is the dominating technology with about 90% of worldwide production of hydro-gen. SICK offers customized gas analysis for process and emission monitoring for industrial processes related to ammonia production.

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The steel in electric arc furnaces bubbles in light orange hues. Flames blaze from the thin gap between the vessel and exhaust manifold;theheatisintense.Thisiswhatsteelworkersunemotionallyrefertoasa“harshenvironment”–butbehinditaresuchextreme conditions for humans and devices that it takes special skills to master them. SICK has tried-and-tested solutions for ex-haust gas measurement in electric arc furnaces – and for the no less intense monitoring of cement kilns – which serve to optimize processes. In addition to safety aspects with gas analysis and leakage monitoring, this means above all energy savings.

>> In the face of increasingly scarce re-sources, even small savings have great importance in heavy industry. The ex-haust gas analysis technology from SICK is setting new benchmarks with fascinat-ing solutions. In principle, the modern fire masters work with the elementary rules of combustion. Perfection, and therefore efficiency, are only achieved when the combustible components of the furnace exhaust gas burn free of residue and without waste. A campfire which smokes and crackles is not near-ly as efficient as one which heats with a light flame. When monitoring furnace processes, SICK relies on this principle and analyzes all gases involved in the combustion for their composition. Per-fect regulation of the gas compositions is subsequently achieved based on these measurements. The idea is the same for the steel and cement production. In both industries is the composition of gas atmospheres in furnaces a deci-sive factor for efficient function. How- ever, due to the different circumstanc-es for the process gas analyzer system METPAX300 for electric arc furnaces and the SCPS system for gas measure-ment directly in the rotary oven, mea-surements are done using different prin-ciples.

Efficient due to optimal combustionTransparency plays an important role in the production of steel and cement for operating entities of electric arc furnac-es and cement kilns. Permanent moni-toring of the process ensures complete insight and overview and therefore en-sures product quality. The data collect-ed during gas analysis is the important

basis for detecting incomplete combus-tion or the development of poisonous by-products and is thereby preventing their creation. This increases both safe-ty and efficiency. In cement production, the temperatures are about 1,400 °C, and these reach up to 1,800 °C in steel production. To compare: The friction-al heat of a spacecraft returning to the Earth atmosphere is right in the center at 1,600 °C. It’s no surprise that a corre-spondingly high amount of energy is ex-pended for such extreme temperatures. A huge potential for savings.

Creating a safe process with sophistication and durabilityBoth systems used by SICK are char-acterized by the high level of durability corresponding to its usage sites. For ex-ample, the SCPS features rugged sample probes whose effective cleaning mech-anisms prevent residue deposits and caking through targeted movements and rotations of the probes. This minimizes maintenance effort and secures the pro-duction process.

But safety aspects, which are to be taken literally, also play a role. The METPAX300 also fulfills another import-ant safety function in crude steel produc-tion. As soon as the balance between the different gas constituents is disrupted, the risk of explosion increases. Leaks in the cooling system can also present a problem. For this reason, the system also detects the H2O concentration and, optionally, the H2 content of the exhaust gas. This sophisticated information is used to quickly and reliably identify leak-ages in the water cooling system in the

HOWTHE“FIREMASTERS”FROMSICKSAVEENERGYWITHEXHAUSTGASANALYSIS

MEASURING TO THE LIMIT

furnace cover or the side panel of the electric arc furnace, therefore preventing massive faults.

Dirty, difficult and dangerous – overcoming challengesSICK is known for its huge portfolio of clean and intelligent solutions in facto-ry and logistics automation. In process automation, on the other hand, things can get really hot. Insiders like to de-scribe the conditions in a striking way as “dirty,difficultanddangerous” - the3Dbusiness. But exactly in this field of chal-lenging ambient conditions, SICK once again proves its own versatility and the ability to find new and innovative paths for and with the customer. The solutions for furnace process monitoring with the METPAX300 and the SCPS are an im-portant testament that even the tough-est conditions can be mastered. And this goes far beyond the initial installa-tion. SICK provides a worldwide service organization with capable experts. The customers can select from a wide range of offers corresponding to their tailored solutions – clean, easy and safe!

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Intelligent sensors ensure efficient and safe production and trouble-free processing along the entire value chain.

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EXHAUST GAS MEASUREMENT FROM SICK CONQUERS THE SEVEN SEAS

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FROM LAKE CONSTANCE TO THE HIGH SEAS

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>> The reduction of emissions is in-creasing in significance in shipping as well. The emission of sulfur oxide (SOx) and nitrogen oxides (NOx) from ships are limited both on a national and in-ternational level. The internationally val-id limit values for SOx were reduced by 85% on 1/1/2020 and apply worldwide for all ships – roughly 55,000 of them. The ship operator can select whether to use low-sulfur fuel or to continue to run the vessel with low-cost heavy fuel oil. In case of the latter, however, an exhaust gas scrubber must be installed and the efficiency monitored with an emission measurement device. This is a major transition for the entire global shipping industry with changes that are unique and result in considerable structural up-heavals.

New territory for proven premium products SICK has been working on ship emis-sion measurements since 2009. The MCS100 produced in Überlingen was used for initial installations; it is other-wise used in power plants or waste in-cineration plants. The ship installation site really was new territory for SICK. The special requirements for the measure-ment technology were mastered. Due to the early arrival in this future market, a new device family was developed in

2013 which is designed only for harsh on-board use. The MARSIC200 and MARSIC300 were launched in 2015. The MARSIC300 features unique at-tributes, is certified by a total of seven international classification societies and therefore has the highest level of accep-tance in the global market of maritime emission measurement devices.

A wave of conversions due to policyAs is so often the case, the market first followed the strict legislation for exhaust gas measurement. In October 2016, the International Maritime Organization (IMO) definitively stated that strict limit values for sulfur oxide would be oblig-atory worldwide from 2020. This was a wake-up call for international shipping companies, which have been continu-ously equipping their ships with exhaust gas treatment systems ever since. When the wave hit, SICK was perfectly pre-pared. In a short period of time, the prod-ucts of the MARSIC series became world-wide bestsellers. Since the production capacities at the Überlingen site were no longer sufficient anymore, a completely new production line was built at SICK's facility in Hamburg. And in line with the increasing sales numbers, SICK is also offering an extensive service portfolio for customer support beyond the mere pur-chase.

Beyond the horizon; decarbonization continuesBut with the changes to environmental protection conditions, there is no land in sight on the seven seas. Shipping is undergoing large upheavals such as decarbonization and digitalization. It is predicted that additional national and international legal requirements will curb operation with heavy fuels. In the mid-term, liquefied natural gas (LNG) will drive worldwide shipping, and in the long-term, synthetic CO2-neutral fuels will prevail. These are challenges which SICK is happy to take on. Especially when it comes to increases in efficiency, energy transparency and certified emission re-porting, there are countless options for using sensors intelligently and sustain-ably. And digital business models with apps and smart solutions are also loom-ing on the horizon.

International shipping emissions have been pushed into center stage over and over again in the last few years. In coastal regions, pollution from sulfur oxides, nitrogen oxides and fine dust is a huge danger to humans and the environment. Until now – and in contrast to almost all emissions sources on land – continuous monitoring of ship exhaust gases was not required. Interestingly enough, the SICK success story in the field of exhaust gas measurement on ships all started in Überlingen, Germany, on Lake Constance.

More information: www.sick.com/maritime

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>> Automated processes simplify phys-ically strenuous work and the sensors integrated in the process in combination with data evaluation reduce error rates. This increases product quality and ulti-mately efficiency and productivity. In the future, humans, machines and autono-mous systems will work even closer to-gether. The transformation is in full swing. That is why it is only logical to rethink safety concepts for protecting humans and adjust them intelligently to new workplace conditions. As individual as the requirements on the different areas and operating processes are, the more individualized the safety solution must be. This affects production, the ware-house, the packing and logistics depart-ment as well as IT, administration or building management.

Certified expertsEmployers must ensure the health, safe-ty and well-being of their employees at work in a constructive, technical and organizational manner. Analysis of weak points and risks assessments must therefore be done in an organized way. For companies, it is therefore more im-portant than ever to get informed about standards and legislation in a timely manner. But there is not enough time and manpower everywhere.

Each process humans are involved in must be proven to be safe. Safety solu-tions minimize operating and process risks. The consequences of avoidable ac-cidents could be dramatic. With the right expertise and a suitable safety solution, for example a machine or production line can be refurbished, modernized or test-

ed very quickly. Certified safety experts from SICK provide their customers with professional project management which follows exactly defined processes. Engi-neering documentation makes the entire process – from planning to execution to approval of the machine – transpar-ent, both for the modernization of exist-ing systems as well as the protection of new plants. The solution portfolio from SICK protects a wide range of hazardous points with a wide selection of sensors, sensor systems and software. A function test with documentation, test report and the SICK VERIFIED SAFETY quality mark completes commissioning. The custom-er receives a fully equipped and opera-tion-ready safety solution.

The externally audited quality seal is now used to label safety projects in a large number of plants and applications. This includes protection of stretch film wrap-pers and packaging machines was well as safety-oriented operating and rear area monitoring of vulcanizing presses in the tire manufacturing industry, or accident and collision avoidance at material trans-fer stations in intralogistics processes.

Closing security gapsProduction and IT are growing closer and closer together. The advantage is that digital networking of the production chain is much more flexible, efficient and less expensive. This simplification

Retrofitting? Modernization? Protecting new plants? Each interruption in machine safety must be executed and documented one-hundred percent. SICK offers certi-fied complete safety solutions for the commissioning of automated guided vehicles, autonomous platforms or human-robot collaboration scenarios. Operator risks are therefore detected and reduced to the minimum in line with standards. For operating entities, this means great relief. Sensor solutions cover other protection options be-yond functional safety.

PERSONAL AND PROPERTY PROTECTION: SICK PROVIDES RELIEF FOR MANUFACTURERS AND OPERATING ENTITIES

PLAYING IT SAFE

also allows for security gaps, allowing hackers to triumph. SICK specifically protects sensors from manipulation so that this does not happen. Even before the development of new products starts at SICK, cybersecurity is considered and encompasses the entire infrastructure, from sensors to safe industrial gateways and production networks into the cloud. Complex cybersecurity measures and established encryption technologies pro-tect sensors from unauthorized access and separate untrustworthy sensor data.

The right equipment for an even higher level of safety In addition to functional safety to protect humans, every company must tackle oth-er safety aspects and perhaps even opti-mize them. With the goal to reliably mon-itor, control, protect and warn. Set the best example with SICK sensor technol-ogy: For collision warning in both indoor and outdoor areas, for explosion protec-tion, on packaging routes, at barriers and approach points, for building safety and security, plants and premises.

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Increase your productivity now:www.sick.com/safe-productivity

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RELIABLE WARNING

RELIABLE SECURING

RELIABLE SUPPORT

SAFE PROTECTION

More relief through remote support: The security architecture of the SICK Remote Service provides a secure, high-perfor-mance remote maintenance connection. This enables reliable remote diagnosis by experts even during operation. Haz-ards are detected early on. Maintenance and calibration are much faster. Avail-ability and life time of the measurement devices increase.

Protecting assets, managing informa-tion: In order to extend response times to intrusions, SICK recommends concentric protection: From perimeter protection and monitoring of the building exteri-or and the interior. Ceilings, walls, and windows are monitored along with doors, gates, and security door systems. SICK is ready for concept development with intelligent sensor systems.

All-round preventive protection: The larger the vehicle, the larger the blind spot and the area that cannot be seen by the driver. Collision warning and user- guidance systems help to prevent acci-dents and to reduce machine damage with downtime. Productivity increases. Thanks to its technological diversity, SICK has been providing assistance with its expertise in front and rear area pro-tection.

Quick and reliable packaging: Every in-dustry has its own special performance requirements. Off-the-rack solutions are often not enough. The modular construc-tion of modern packaging machines re-quires an intelligent and flexible safety concept. SICK safety solutions ensure the protection of humans and machines, thereby optimizing production, reducing machine footprint requirements, and decreasing downtime. From the rugged, moisture-proof photoelectric sensor for glass identification via intelligent cam-era sensors, checking packaging ele-ment position through to protecting ro-botic loaders with safety laser scanners – SICK sensors and systems meet the requirements of the packaging industry.

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RELIABLE CONTROL

RELIABLE PROTECTION

SAFE DETECTION

RELIABLE MONITORING

Free navigation of service robot on ship decks

Vehicles posing a fire risk must be detected and unloaded before they leave with a ferry.

Not for everyone: Only authorized per-sons or vehicles may pass. Barriers con-trol the modern day-to-day running of the factory, because security on the factory premises plays an important role for a smooth and efficient flow of business processes. SICK leads with detection products and with a broad portfolio of solutions SICK also supports the devel-opment of holistic and standard-compli-ant monitoring concepts.

Setting limits for explosions: Regula-tions and standards for the prevention of explosions differ worldwide. SICK there-fore continues to develop and certify its devices according to international stan-dards. The measurement technology from SICK is being employed successful-ly, and the wide variety of devices for gas and dust measurement offers tailored solutions, even under the most stringent measurement conditions.

The air is clean: Environmental and cli-mate protection is currently taking center stage in economic orientation – doubt-less a herculean task with international character. The standards and regula-tions for emission monitoring and re-porting are getting stricter in nearly every country in the world. In order to comply with requirements, many customers are turning to SICK to cover their needs for monitoring solutions for dust, volume flow and continuous gas emissions.

Driving without a driver: Safety laser scanners have prevailed worldwide for the safe detection of people around au-tomated guided vehicles. SICK offers a complete product portfolio with a variety of different scanning ranges and fittings. Up to 128 freely-definable protective fields allow for fine-tuned adjustment of person detection to the current driving scenario. The vehicle thereby achieves its maximum transport performance. Forward warning fields trigger speed re-duction as soon as a person or an ob-ject is detected. The vehicle immediately spots when the protective field zone is reached.

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OPTIMIZING PROCESSES IN SOLAR POWER PLANTS

SOLAR ENERGY

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>> Solar power plants should produce as much power as possible. Thousands of reflectors are in operating full swing all over the world. In a first-class plant, the number of reflectors even reaches well into the six-digit range. The expansive power plants are often located near to the equator and are therefore often far away from civilization. This makes it clear as daylight that all components installed in the plant must work free of faults for long periods of time. Service work for re-mote regions cannot be organized and performed in a hurry.

That is why you are always on the sun-ny side of the street with reliable sen-sor performance. And SICK sensors are known for their reliability. They measure accurately and stably, and also score points with their long service lives. And, in addition, the SICK Remote Service program is a welcome offer and a ser-vice promise. Not only does commis-sioning and maintenance work run as a matter of course, but spur-of-the-mo-ment service support is also fast and flexible. At the click of a mouse, experts fix problems in a timely manner. The customer-specific cloud solutions are designed in accordance with strict safety standards. The combination of intelligent

sensors, quick service and networking of data reduces costs and also increases plant efficiency: From the solar cell to the heat exchanger to back-up gas fired power plant. And should on-site service still be necessary, the web-based service platform noticeably minimizes planning and setup times. Solar tracking for higher energy yieldIn heliostats, parabolic troughs and solar modules in a photovoltaic solar park, re-flectors and solar cells must be aligned to the sun all day. The sensors measure the tilt or rotational movement of the reflectors and solar cells in one or two dimensions without making contact so that they can track the sun using the po-sition data.

Like real outdoor professionals, the sen-sors also measure on hot, icy, dusty or wet days. The electronics are highly resis-tant and therefore nearly failsafe. Using encoders, the mirrors can concentrate the sunlight precisely on the solar tower, which then utilizes the energy according-ly. With concentrated solar thermal ener-gy, thousands of mirror systems bundle solar radiation on an absorber surface. At this focal point, molten salt or thermal

oil heats up and then flows through lines into heat accumulators or directly to the steam power plant.

The TDC (Telematic Data Collector) gate-way system collects and saves measure-ment data from sensors using various interfaces. This data flows non-stop to a server or the customer cloud via mobile communication integrated in the system. The incoming and outgoing data increas-es transparency and can be utilized to increase productivity in downstream pro-cess optimization sections. SICK offers optional customer-specific cloud solu-tions for this purpose.

Depending on the system capacity and location, solar power plants can supply entire regions with environmentally-friendly energy all day long. Operating entities are not happy until systems are working optimally – with a high degree of efficiency, reliable avail-ability and profitability. That is why the use of sensors is absolutely necessary in many points of the process chain. With the right equipment, the sun shines every day.

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The future of solar energy continuesPower generation using solar cells is be-coming increasingly attractive amongst regenerative energies. In 1958, US Americans started the solar revolution byequippingthe“Vanguard1”researchsatellite with solar modules. Satellites continue to use solar energy today. This success was at the same time the pre-cursor for solar energy on earth – and then back up into the air. Swiss pilot André Borschberg, in his “Solar Impulse 2“ powered by solar energy, flew 8,300 kilometers nonstop between Ja-pan and Hawaii.

This has been the world record since 2015. The development of the solar mar-ket remains highly innovative with rapidly growing technology development.

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Source: IEA All Rights Reserved. www.iea.org/reports/world-energy-outlook-2019/electricity

Coal Gas Oil Nuclear Hydro Wind Solar Other renewable sources

POWERGENERATIONACCORDINGTOFUELANDSCENARIO,2018‒2040

Stated policies Sustainable developmentThousand TWh

Efficiency increase in heat accumulatorsHeat exchangers in heat accumulators or heat conversion plants generate steam to drive the turbines to generate power. The measurement quality of the steam flow frequently involves making compro-mises. Inaccuracies in the flow rate and pressure loss are tolerated. Even leak-age hazards are often not precisely iden-tified. But this does not need to be the case. The FLOWSIC mass flow measure-ment has proven itself in challenging and high-quality installations for steam quantity measurement. These ultrason-ic sensors do not lose pressure, which results in higher system availability. The FID analyzer from SICK monitors organic carbon in low concentrations to protect against leaks in the N2 blanketing sys-tem. The MCS300P process gas analyzer checks whether steam or water escapes into the heat transfer oil.

Who works during the night?The sun delivers so much energy that so-lar power plants can produce sufficient power and heat and are a real alternative to conventional power generators. With SICK, you can have your reserve power generation in attached gas-fired power plants under control. Monitoring of the natural gas flow to or within the gas-fired power plants with ultrasonic gas flow me-ters is also important for correct invoic-ing. Nobody wants to pay too much. And with products for emission monitoring, complete solutions can be created from a single source.

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Special sensor variants reliably detect both the strongly reflective wafers as well as the cells that absorb the light in the production of solar cells.

2D vision solutions from SICK monitor posi-tion and possible breaks when handling solar cells.

Improved automation in solar cell productionSICK sensors are also qualified for the production of solar modules – from sim-ple detection tasks to significant sensor systems in a complex production pro-cess. Cameras and software are special-ly designed for very low-reflectance solar cells and modules. Intelligent track and trace solutions have been proven in qual-ity control. In production, sensors protect humans from dangers in the workplace.

For the last few years, there has been a trend towards more flexible modules. In production, flexible materials are being used as a replacement for rigid and very breakable glass. The flexible modules are much thinner than conventional solar modules. However, their production con-siderably reduces energy input, which in turn significantly reduces production

costs. Without sensor technology, the fragile modules can quickly be damaged beyond repair in automated production processes.

The integration of flexible modules in roofing materials and facade elements enables cost-efficient system solutions.

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FEEDING BULK MATERIALS ON A RUNNING BELT

DOSAGE AND MIX MUST BE RIGHT

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>> The conveyor system in the cement plant is impressively large. If all band lengths were added up, the total dis-tance would be several kilometers. Conveyor belts are usually in operation around the clock, bringing material to the right place in a controlled and efficient manner. A large number of monitoring tasks are carried out along these routes. The long transport route does not auto-matically have to be accompanied by a higher metrological challenge. It is often the smaller conveyor belts that create special tasks for the measurement tech-nology. The cement plant belonging to HeidelbergCement AG in Lengfurt, Ger-many has found a powerful solution for short routes with the Bulkscan® LMS511 from SICK and is precisely regulating the feed of secondary raw material on the raw meal belt.

From the bunker to the transfer point to the main transport belt, measurement of bulk materials with rugged measure-ment technology is required. It is very dusty in the hall in which the conveyor belt transports additional ferrous mate-rial on a length of only a few meters. The conveyor was originally used for different purposes and now, after a plant conver-sion, it dispenses additives. To comply with the defined clinker mineralogy, the output values of the installed measure-ment technology must be absolutely re-liable so that the cement properties are correct in the end. For a conventional belt scale, it is nearly impossible to identify the mass flow of the material. The belt is only 60 cm wide and the belt loading sys-tem is only a few centimeters high. In ad-dition, installing a belt scale is time-con-suming and cost-intensive and involves large mechanical modifications. The

Bulkscan® LMS511 is mounted above the conveyor belt. The system must not be at a standstill during installation and, in contrast to belt scales, the conveyor belt does not need to be separated.

Quick viewThe Bulkscan® LMS511 measures from above. Because everyone knows you have the best view from there. The non-contact, laser-based volume mea-surement system above the conveyor belt thus provides an exact overview of the transported quantity. With the proven 5-echo pulse technology, the laser vol-ume flow meter generates a reliable flow signal using the laser’s time of flight and the belt speed information. The technol-ogy filters out interfering echoes caused by dust, fog, glass or precipitation, there-by delivering reliable measurement re-sults. In addition to the volume flow, the sensor also delivers the mass flow in combination with the material density. It is completely irrelevant how fast the belt is running or which bulk materials

are being transported. Furthermore, the Bulkscan® LMS511 contributes to opti-mal operation of the conveyor belt due to its integrated detection function for center of gravity, material height and belt drift and the associated reduction in downtime. Even falling bulk material can-not harm the sensor due to its position over the conveyor belt. The sensor per-fectly underlines the smooth application solution from SICK.

The Bulkscan® LMS511 has exceeded the customer’s expectations: The exact measured values of the laser scanner transmitted to the control room ensure precise control of the dosage in the in-terface. The smooth, optimal production process saves a huge amount of work, time and money. And the maintenance effort of less than an hour a year is also a plus.

Sensors from SICK measure the volume flow of raw material on the conveyor belt from the bunker onto the main conveyor belt to the combustion process and thus ensure the metered supply of secondary material.

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WIND OF CHANGE.

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The shipping industry is facing a period of major change such as decarbonization and digitalization. SICK is ready for the imple-mentation of these changes and is supporting shipping companies and shipbuilders with countless possibilities for employing intelligentandsustainablesensors:forbetterenergytransparency,moreefficiency,effectiveloadingandunloading,andreliableobject and hazard detection. With cloud solutions. There’s something new on the horizon: wind for ship propulsion. Sensors from SICK are ahead of time and already monitor sail tension and alignment. We think that’s intelligent. www.sick.com/maritime

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Measurement errors, uncertainties and lost gas (gas that is lost in the asset) from leakage, inefficient metering sys-tems, pressure changes or gas quality changes quickly add up to considerable financial losses.

Highly accurate and reliable measure-ment at production, distribution and custody transfer points allows for more transaction transparency and control over costs and processes. It is essential for meeting international regulations and requirements, and, ultimately, for mak-ing most efficient use of natural gas as a commodity.

Flow metering systems by SICK employ leading ultrasonic metering technology and are delivered as turnkey solutions. SICK offers solutions that can be inte-grated into every installment. Our port-folio ranges from small scale metering runs to large scale metering skids, in-cluding stationary analyzer systems.

Flow metering systems by SICK employ leading ultrasonic metering technology and are delivered as turnkey solutions. SICK offers solutions that can be inte-grated into every installment. Our port-folio ranges from small scale metering runs to large scale metering kids, includ-ing stationary analyzer systems.

Factory-installedoptions

Gas compositionmeasurement

Volumemeasurement

Pressuremeasurement

Temperaturemeasurement

Flowcomputing

Supervisorysystem

FLOWRUN600 – O O O O –

FLOWSKID600 O O O O O O

FLOW METERING SYSTEMS

AN IMPORTANT KEY COMPONENT TO INCREASE ENERGY AND RESOURCE EFFICIENCY Flow metering systems from SICK incorporate leading ultrasonic metering technology and are delivered as customized turnkey solutions in the form of metering skids or metering runs. The use of the ultrasonic flow meter, as the heart of the system, ensures precise measurement of the gas. The requirement for lowest measurement uncertainty will fulfill all requirements for custody and non-custody transfer purposes.

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Consultancy Feed

Design and Engineering

Project Management

Manufacturing Calibration and Integrated Tests (FAT/SAT)

Shipping and Packaging

Start-up and Commissioning

Training and Lifetime Services

Weitere Informationen: www.sick.com/8024139 www.sick.com/flow-metering-systems

SICK follows a solution-driven 360° ap-proach, providing customers with gas metering solutions tailored to their indi-vidual requirements. Our customers ben-efit from thorough personal consultationand flexibility throughout the entire proj-ect, from planning to lifetime mainte-nance plans. They also enjoy the advan-tages of having all their demands met from one source: improved schedules, lower costs and lower risk.

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With Smart Data Solutions, SICK already offers data-based solutions today for the in-dustry of tomorrow. These solutions detect, visualize and monitor data from sensors, machines and plants. This foundation makes it possible to precisely predict machine and plant events. Two examples of our data-based services are:

Installed Base Manager: Digital recording of your real assets

With this app, you digitally record all your assets, saving valuable time. With the SICK Installed Base Manager, recording serial numbers, positions or photos is also very easy. All product information is only a few clicks away in the digital world. The correct information concerning your assets is therefore quickly accessible to you.

Monitoring Box: Monitor and increase performanceThe Monitoring Box offers virtual access to sensors and machines and improves on-going production operation every day. With the history view and log book, no events or developments pass you by. The Monitoring Box monitors integrated devices of your company and ensures hundreds of pieces of sensor and machine data. Continuous status monitoring and notifications if limit values are exceeded mean you can react in a timely manner and thereby reduce downtime.

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MAKING DATA TRANSPARENT

More information: www.sick.com/smart_data_solutions

SICK IS AN INNOVATIVE COMPANY. IT PROVES THIS EVERY DAY, WITH IDEAS AND PLANS AND IN NEW PRODUCTS AND SOLUTIONS. YOU CAN SEE HERE WHAT WE ARE CUR-RENTLY WORKING ON, WHAT IS OCCUPYING US AT THE MOMENT AND WHAT WE WILL BE DOING IN THE FUTURE. TO SAY IT IN THE LANGUAGE OF PROCESS AUTOMATION: LOOK AT WHAT WE HAVE IN THE PIPELINE.

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FULL TRANSPARENCY IN THE MATERIAL FLOWLocalization provides transparency in all areas of automation: Even in partially and non-automated areas, SICK is providing a new localization system. Based on ultra broadband technology, it deter-mines where which goods and products are currently located.

The data recorded and merged by the system are then available for evaluation thanks to the Asset Analytics platform developed by SICK. Asset Analytics offers a decisive additional advantage, as it gathers the data recorded by the hardware components, merges it and provides it to the user for further use – locally or in the cloud. Knowledge which is becoming increasingly interesting for logis-tics in process automation and is already being substantiated by customers from the mining field.

News from the world of data: Read stories, dive in, and get to grips with Sensor Intelligence. www.sick.com/blog

BIG DATA, DEEP LEARNINGDeep Learning technologies improve the functionality of sensors based on self-learning algorithms. In this way, sensors perform intelligent acts in the automated detection, testing and classification of objects or features which were reserved for humans until now. Humans and machines are grow-ing closer together.

The concept of the sensor specialized with artificial intelligence can in principle be used on stan-dard sensors such as inductive proximity sensors, photoelectric retro-reflective sensors, ultrasonic sensors and others. The findings collected in logistics automation also make the leap to process automation possible.

More information www.sick.com/8024008

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TRANSIC EXTRACTIVE MONITORS THE OXIDATION PROCESS DURING DESULFURIZATIONIN THE MEROX® PROCESS

CLEAN EXHAUST GAS THANKS TO EXTRACTIVE OXYGEN MEASUREMENT

The reduction of the sulfur content in fossil fuels such as natural gas and oil is one of the most important environmental require-ments for clean air. There are several established processes for removing sulfur components from product flows in refineries and natural gas processing plants. One of the processes for desulfurization used all over the world is the MEROX® process. The right amount of oxygen is essential here – and this is a home game for the reliable and easy-to-integrate gas transmitters from SICK.

>> Mercaptanes and hydrogen sulfide smell bad – to be honest, they stink to high heaven. Processes in oil refineries or natural gas processing plants which remove mercaptanes or hydrogen sulfide are referred to in general as desulphur-ization processes (sweetening) since this results in products which no longer ex-hibit the sour, foul smell of mercaptanes and hydrogen sulfide. The liquefied hy-drocarbon disulfides can remain in the

processed products or be used for other processes after separation.

Old standards and the same old problemsParamagnetic O2 analyzers are used by default in many plants all over the world. For many plant operators, the alternative is a weekly analysis in an off-line mea-surement system in a lab. However, both approaches for oxidation monitoring

have considerable weaknesses: After disulfide separation, sampling is a very challenging task. And it is sometimes im-possible to keep all contamination away from the analyzer. Paramagnetic O2 an-alyzers are very sensitive to contamina-tion by oil, moisture and other adhesive materials. If oil penetrates into the mea-suring chamber, it cannot be cleaned, or only with difficulty, or the entire cell has to be replaced if it was damaged by

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droplets of liquid. Only with a high level of monitoring and the use of a special filter before the analyzer can penetration of liquid into the measuring chamber be prevented. Both maintenance and repair as well as the replacement of the ana-lyzer, if needed, are extremely costly and lead to lower availability. Due to these problems, many operators choose the alternative of external lab measurement and hence for a more than sub-optimal solution with all its disadvantages such as limited availability, high costs and enormous delay times due to lengthy analyses.

The easy answer from SICK: TRANSIC ExtractiveThere is an easy answer to ensure bet-ter availability even in the demanding MEROX® process: The TRANSIC Extrac- tive from SICK is a rugged analyzer sys-tem for extractive oxygen measurement. It uses modern diode laser spectrosco-py (TDLS) to very accurately measure the oxygen concentration in the air vent downstream of the disulfide separator. Due to its compact design, the TRANSIC Extractive can be used easily under diffi-cult conditions and in contaminated gas-

THE MEROX® PROCESS

MEROX is an acronym for mercaptane oxidization and describes the catalytic process developed by UOP which removes mercaptanes from LPG, propane, butanes,lightnaphthasandkeroseneinoilrefineriesandnaturalgasprocess-ingsystemsandconvertsthemintoliquidhydrocarbondisulfides.Inthisspe-cificcase,aTRANSICextractiveanalyzerfromSICKisusedinaMEROX® unit for light cracked naphtha.

es. The TRANSIC is well-protected from oily droplets due to the sample handling in front of the analyzer. Should drop-lets still reach this point, the integrated TRANSIC sinter Teflon filter prevents penetration into the device measuring path. The reliable and continuous oxygen measurement system delivers results as needed and not only when a laboratory is available.

Explosion protection as a plusIn addition to air regulation in mercap-tane oxidization, the oxygen value is used as a safety measurement to prevent the formation of a self-igniting mixture if ther-mal combustion exists downstream of the exhaust air. To keep the oxygen con-centration below five percent by volume, a sufficient amount of fuel gas is added to the vent gas before oxygen measure-ment in this case. A fire can sometimes only be prevented by ensuring the ab-sence of oxygen. It is precisely this that TRANSIC Extractive reliably monitors.

More information: www.sick.com/chemicals

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FROSTY GAS MEASUREMENT

SICK LOWERS BOIL-OFF GAS LOSSES FOR ENAGAS

In the Huelva plant, Spain’s largest LNG provider was experiencing unexpectedly high boil-off gas losses. The reason was strong turbulence due to unfavorable piping arrangement which was influencing the FLOWSIC600 ultrasonic gas flow meter. Neither pre-calibration nor removal were economically feasible. Instead, SICK solved the problem at low cost using a correction function based on CFD analysis. Since then, the device has been perfectly measuring the evaporation gas at –120 °C.

>> Liquefied natural gas (LNG) is consid-ered one of the most interesting ways to supply countries or industries with CO2-low energy – independent of politically controversial overland pipelines. Lique-fied natural gas is created when natural gas is cooled down to below ‒161 °C (‒258°F).Itthenonlyhasonesix-hun-dredth of its original volume and can be transported anywhere with tankers. Since cooling cannot always be kept con-stant, evaporation or boil-off gas (BOG) is sometimes created in the tanks on land and on ships. It is usually used as reserve energy or burned off to prevent overpressure.

Spain has been covering 75% of its en-ergy needs with liquefied natural gas for

years. Spanish energy group Enagas op-erates six LNG terminals in Spain alone. The delivered LNG is stored here and then transported by truck or regasified and fed into the 11,000 kilometer-long pipeline belonging to the company. Evap-oration gas in the storage tanks can be economically recooled and burning off can be mostly avoided.

To most accurately calculate the BOG volume before the flare gas, the FLOWSIC600 2-path gas flow measure-ment technology from SICK was used in the40”boil-offgaspipeline intheLNGterminal in Huelva, Spain. This is an ideal line-up since the device works su-perbly even at low temperatures down to ‒194°Canddoesnot causepressure

loss. After a few months of use, it was discovered that the total balance of the plant showed gas losses (unaccount-ed-for-gas) of 0,18%. A small number, but it corresponded to a monetary loss of 2 million euros a year.

Enagas asked SICK to help them find the cause. After an in-depth plant in-spection and analysis of the installation conditions, it turned out that there was strong turbulence in the flow at the in-stallation site of the FLOWSIC600. The cause were two 90° pipe bends before the inlet zone. This construction was not known at the time of device design. The pronounced turbulence influenced the measurement result of the 2-path mea-surement device.

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Solution options were then developed. The option of calibrating the flow per-turbation was eliminated due to the de-vice conception and the large nominal pipe size. Another option was to extend the measuring paths, which would have resulted in mechanical modifications. Finally, Enagas and SICK decided on a solution with CFD (computational fluid dynamics). In this solution, the plant was reconstructed with a computer simula-tion and the flow profile in the measure-ment section was calculated. This made it possible to find the measurement er-ror. Result: The analysis showed a mea-surement error of up to 7.4%.

In the last step, the computer simula-tion was used as a basis to determine a correction function. The transfer of this function into the real device was a com-plete success. The balanced gas loss was reduced by the correction of 0.1%,

or a million euros a year. The scale was acceptable for Enagas.

The FLOWSIC600 ultrasonic measure-ment technology has now been reliably measuring evaporation gas at –120 °C for nearly 10 years. The CFD analysis helped to reduce the influence of unde-sired installation effects.

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The Norwegian cement manufacturer Norcem, a member of the worldwide group HeidelbergCement, wants to do more for the environment and emit even fewer pollutants. To ensure that everything is done in accordance with legal requirements for low limit values, innovative dust measurement devices from SICK perform a decisive measuring task after the flue gas scrubber. Only when the plant operator Norcem Kjøpsvik is satisfied the high requirements are fulfilled.

>> Water droplets or dust particles? Only excellent vision can tell them apart. Hu-manly impossible? That's why there are measuring instruments that are special-ized in measuring dust concentrations in wet gas. However, not all dust measuring devices control reliably to ensure that the emission limits can be compliant. The exhaust gas after scrubber systems is usually very cold and saturated with water. This fact challenges the measur-ing technology.

Great things are being done in the Arctic Circle. In the middle of the harsh Norwe-gian remoteness, the world's northern-

most cement plant – and the only one within a radius of 1,000 km – is taking on a remarkable task. Norcem Kjøpsvik produces cement for the domestic mar-ket. This is often not easy. The routes toward 68 degrees north are cumber-some and time-consuming. Because of the distance alone, the process chain and equipment must function perfectly. In addition, the sulphurous limestone has caused problems in the past. The sulphur content was too high and the plant increasingly exceeded the permit-ted emission limits. The limestone was extracted from the adjacent quarry. This meant short distances that made

economic sense. Now a constructive re-think was called for. First of all, Norcem changed its mining plan and extracted low-sulphur limestone from other ar-eas, which significantly extended the transport distances. In the long term, this was not a sustainable change and therefore only a temporary solution. The situation transformed abruptly, however, when Norcem was able to invest in a flue gas desulphuristation (FGD) plant based on a seawater scrubber with the support of the state environmental fund Miljøfondet. This technology was used to remove SO2 from the flue gas with a high separation rate. This made lime mining

MEASUREMENT OF PARTICULATE EMISSIONS IN FLUE GASES

SOME HUNTERS LIKE IT WET …

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… SOME LIKE IT DRY

in the adjacent limestone quarry possi-ble again. Since then, the dust sensor technology from SICK has been measur-ing concentrated in the wet gas, confirm-ing Norcem Kjøpsvik's emission limits, which are now in the green range. Emission Reporting Clean exhaust gas and compliant emis-sion limit values are the cornerstones of success. The gas cleaning system was ready for operation in short time. The contract with the equipment supplier was signed in autumn 2017, installa-tion work began in summer 2018 and hot commissioning took place in May 2019. In the meantime, more than 95% of the sulphur dioxide is washed out. The maximum SO2 concentration at the stack outlet is limited to < 50 mg/m³, which is an excellent value. The plant uses only seawater instead of chemical absorbents. However, this challenges the continuous dust concentration measure-ment. What is a water droplet? What is a dust particle? In the wet gas duct, it is indistinguishable for standard devices. Accordingly, the inaccurately measured values of such devices are also unac-ceptable for emission reporting. The

measurement performance of the dust monitor from SICK, on the other hand, is light years ahead of the standard, because the FWE200DH is designed especially for difficult measurement con-ditions such as these.

Measuring dust at its best According to the optical principle, the scattered light intensity determines the dust concentration. Disturbing water droplets must be removed before the measurement. The FWE200DH extracts sample gas from the exhaust gas flow. In the bypass system, the water drop-lets evaporate so that they no longer hinder the accurate measurement. The exhaust gas flows back into the gas duct after the measurement. The FWE200DH measures in many applications and in-dustries worldwide, but the special in-stallation conditions at Norcem Kjøpsvik were a new challenge for SICK's particle analyzer team. The tight geometric space conditions in the mounting flange made the use of a usual measuring gas probe for exhaust gas extraction impossible. For correct functioning, the sample gas probe must be mounted facing down-wards, which would not have been pos-

>> Not only sulphur volatile gases are relevant to the climate. In raw material and fuel there are many pollutants which are released by the pyro process. In ad-dition to the high proportion of sulphur volatiles from the raw material, the high chlorine input from alternative fuels also causes problems in cement production. Switching to alternative fuels with bio-mass reduces carbon dioxide emissions, but in return usually increases the chlo-rine input and the risk of blockages in the

cyclones. To ensure that the preheater functions without restrictions, a bypass system extracts up to 60% of the process gas. This removes gas components that disturb the process from the pyro pro-cess. This gas stream is later fed back into the process where the raw meal is added. In normal operation Norcem op-erates the bypass with less than 10% of the exhaust gas volume.

Fabric filters are a particularly efficient and frequently used filter technology. The dust-laden flue gas flows into the filter chamber and passes through sever-al filter bags. The coarse particles fall by

sible with a standard probe design. This hurdle could only be overcome with a customer-specific probe geometry pro-vided by SICK. During commissioning, it became apparent that the sample gas probe could be mounted without any problems. This made it possible to link the functional requirements with the real installation conditions. The facility is still running smoothly and reliably today.

In addition to the high sulphur volatiles from the raw material, the high chlorine input from alternative fuels also causes problems in cement production.

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gravity into the hopper. The fine particles accumulate on the surface of the per-meable filter medium and form a layer of dust, usually called filter cake. Com-pressed air periodically cleans this filter cake. However over time, small holes can form in the fabric. As a result, the gas enters the exhaust air unfiltered and worsens the emission limits.

Measuring dust with comfortable easeTo prevent this from happening the DUSTHUNTER SB30 measures after the filter of the bypass. The dust measuring device reports in real time, signaling when filters are damaged. The scattered lightmeasuringprinciple− in this casewith backward scattering − monitorsconstantly and is not influenced by the flow speed or the dust particle charge. This is an important advantage over

"Regarding the dust analyzers, there is not much to say. We oversee the equipment every fourth week

and we haven't had a single problem since we installed them."

Erik Nilsen, Maintenance Manager NORCEM AS

other measuring methods, such as the triboelectric principle. The self-monitor-ing function is particularly user-friendly. Automatic test cycles reduce mainte-nance requirements and ensure that pro-cesses run smoothly. Norcem Kjøpsvik also found installation and commission-ing to be effortless. After a few hours, the DUSTHUNTER was ready to start work-ing. The dust measuring device was mounted on the exhaust duct on one side only. The additional effort for special alignments, as required for cross-chan-nel transmission dust analyzers, was completely eliminated. Since this DUSTHUNTER SB30 has no measur-ing probe, so that a longer instrument lifetime is guaranteed. This is because aggressive gases would attack a probe and corrosion and abrasion would be the result.

The significantly higher detection sen-sitivity of the DUSTHUNTER SB30, com-bined with the cost-effective installation and maintenance, is the recipe for suc-cess across the board: increased perfor-mance with reduced total costs over the entire life cycle of the device.

The efficiency and profitability of the plant in Kjøpsvik has increased signifi-cantly – not only at the heat exchanger but in the entire exhaust gas cleaning system. Years earlier, SICK had already supplied gas analyzers for the rotary kiln of Norcem Kjøpsvik. Out of conviction, Norcem also decided to use dust mea-surement technology from SICK.

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Stricter emission limit values are not only the order of the day; they also drive technological research and development. This results in the newest BAT (best available technique), which in turn influences future legislation. In accordance with the emission guidelines of the European Union, environmentally-relevant industrial plants in particular must operate in accordance with the best available technique. SICK expertise helps with implementation.

The Industrial Emissions Directive of the European Union must be complied with as legislation both on the national and EU level. The goal is to prevent pollutant emissions into the air, water and soil. The “bestavailabletechnique”(BAT)isusedhere. The BAT should not only guarantee the best possible environmental protec-tion, but also consider the economic and technical feasibility for the operator or industrial plants. When defining the BAT, not only the individual technical compo-nents, but also the interplay between design, maintenance and production are evaluated.

Many options require much expertiseDepending on the segment industry, emissions differ, and a corresponding reference paper is therefore created for each industry (best available technique reference = BREF). 32 different indus-tries are currently described. These doc-uments are updated regularly. In most cases the revision is done within the specified eight years. So, for example the new version of the Large Combus-tionPlantBREFinJune2018.TheWasteIncineration BREF was published by the European Council (EIPPC - Integrated Pollution Prevention and Control Bureau)

EXPERTISE IN DUST, GAS AND FLOW MEASUREMENT

BREF: WHEN THE BEST AVAILABLE TECHNOLOGY BECOMES THE REFERENCE POINT

BREF: SIMPLE IS NOW POSSIBLE

by the end of 2019. This must be made into a national law within four years.

The application of the guidelines de-scribed in the BREFs requires extensive knowledge about limit values and the re-quired measurement components. The many years of experience and expertise of SICK in all areas of dust, gas and flow measurement helps during consultation.

More information: www.sick.com/8024120

Who said the BAT reference document is complicated? With our BREFSelectortoolcertifiedbyTÜVRheinland,yougettheemission limit values tailored to your plant within one minute. From the 986-page LCP Directive, the 747-page working draft for waste incineration and the 45-page BAT cement reference document, we have extracted the emission limit values for thedifferentplanttypeswhiletakingintoconsiderationallrelevant notes and exceptions in order to create a user-friend-ly database.

Try us out and make an appointment with your local sales contact to get a free consultation!

www.sick.com

SICK AGErwin-Sick-Str. 1 | 79183 Waldkirch, Germany Phone + 49 7681 202-0 | Fax +49 7681 202-3863

Visit us online: www.sick.com/industries-pa

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transformation through transparency · 2021. 3. 27. · silke ramm de camejo · matthias winkler...

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